Simulation and Optimization of T-shaped Tube Internal High Pressure Forming Based on Response Surface Method

During the process of internal high pressure forming, the T-shaped tube has some defects such as rupture and wrinkle. The forming process was studied by the combination of experiment and numerical simulation. An optimization method based on the response surface method was presented, that is taking the internal pressure, the left and right feed rate and the fillet radius in the high-pressure forming process of T-shaped tube as the optimization factors, taking the bulging height and minimum wall thickness of the T-shaped tube as the evaluation indexes, the fitting equation between factor and objective function was constructed by response surface method. After analyzing the variance of the response surface model, the optimal parameter matching relation in the high-pressure forming process of T-shaped tube was obtained. The test was carried out by using the optimal parameter matching relationship,and a sample of T-shaped tube with a bulging height close to 1 times the diameter of the tube and a maximum wall thickness thinning rate less than 20% was obtained.